Error And Mistake Proofing
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Mistake Proofing Examples
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Mistake Proofing Levels
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The concept was first put to widespread use by Shigeo Shingo within the Toyota Production System (TPS).Objective:PREVENT a defect from occurring and when this is not possible, DETECT the defect every time one occurs. There
Mistake Proofing Exercise
are various levels, effort, and costs of error proofing. The team needs to identify
Mistake Proofing Principles
the optimal states and examine feasibility of implementation in the new product or process KPIV's. He recognized three types of mistake proofing ppt poka-yokes: Contact method - identifies defects by testing product characteristics.Fixed-value - a specific number of movements every time.Sequence method - determines if procedure were followed. Defects found in later operations or steps of a process https://www.moresteam.com/toolbox/error-proofing.cfm have more costs associated with them. There are more materials, labor, overhead, previously reworked product that are at risk. Ultimately if the product gets to the customer as a defect, the intangibles, such as reputation, can exceed the tangible cost.For example, a carbon monoxide detector will not be as effective if the inputs of dangerous and tolerable PPM levels are not known, or if the proper location for http://www.six-sigma-material.com/Mistake-Proofing.html installation is not clear.GOOD: Detect defect before proceeding to next step.BETTER: Detects defects while in process at an operation.BEST: Prevent defects from occurring at all.Each process should have error-proofing to ensure defects are not passed on to the next step and that each operation has mistake proofing in place to ensure only defect free parts are accepted in. Connection to the FMEA The FMEA has three categories of:1) Severity2) Detection3) OccurrenceMistake Proofing is applied to reduce the scores in Detection and Occurrence.Once a mistake proofing device or method is proven it is important that the GB/BB follow up with the Quality Department to update the company FMEA if applicable. Risk reduction is another soft savings benefit from a Six Sigma team (reducing the RPN number of a failure mode).The Six Sigma team also updates their own project FMEA and this becomes the Revised FMEA in the CONTROL phase. Examining the Cost of Defects Their is an initial cost to implementing poka-yokes just like their is a significant cost to implementing SPC. However, this cost will be more than offset in the long term stability and performance of the output. In other words, if the correct poka-yokes are invested these will help reduce varia
Events Submit an Event News Read News Submit News Jobs Visit the Jobs Board Search Jobs Post a Job Marketplace Visit the Marketplace Assessments Case Studies Certification E-books Project Examples Reference Guides Research Templates Training Materials & Aids Videos https://www.isixsigma.com/tools-templates/poka-yoke/how-mistake-proof-are-your-processes/ Newsletters Join71,726 other iSixSigma newsletter subscribers: MONDAY, OCTOBER 10, 2016 Font Size Login Register Six Sigma Tools & Templates Poka Yoke How Mistake Proof Are Your Processes? Tweet How Mistake Proof Are Your Processes? Kerri Simon http://www.npd-solutions.com/mistake.html 24 It was a Japanese manufacturing engineer named Shigeo Shingo who developed the concept that revolutionized the quality profession in Japan. Originally called "fool proofing" and later changed to "mistake proofing" and "fail safing" so employees mistake proofing weren't offended, poka yoke (pronounced "poh-kah yoh-kay") translates into English as to avoid (yokeru) inadvertent errors (poka). The result is a business that wastes less energy, time and resources doing things wrong in the future. What Is Poka Yoke? Poka yoke is one of the main components of Shingo's Zero Quality Control (ZQC) system – the idea being to produce zero defective products. One way this was achieved is through the use of poka error and mistake yoke; a bunch of small devices that are used to either detect or prevent defects from occurring in the first place. These poka yoke methods are simple ways to help achieve zero defects. Who Develops Poka Yokes? Here's the beauty of the methods…anyone, from manager to line supervisor to line employee can develop a poka yoke. (Alright for you transaction people out there…anyone, from regional sales manager to sales associate to document specialist). All it takes is the empowerment of employees, as well as a little instruction around what makes a good poka yoke. What Does a Poka Yoke Look Like? Poka yoke looks different in each situation. I'll try to present a few different scenarios for poka yoke use. Let's take a transactional situation and analyze a few parts of it. Say, for instance, we're at the signing of a bank loan by a lucky couple closing the mortgage on their first home. Example 1: The lucky couple picks up the pen to sign, but when they depress the top of the pen to extend the writing part it malfunctions because the spring is missing. A poka yoke could have prevented this situation. If all pieces of the pen were presented to the assembler in a dish, a simple poka yoke would be for the assemble
Assessment Product Development Process Definition and Improvement Portfolio Management System and Planning Quality Function Deployment Consulting and Training Reducing Time-to-Market Requirements Definition and Product Planning Stage / Phase-Gate Process Target Costing Consulting and Training Voice of the Customer NPD Training All NPD Training Best Practices of New Product Development Workshop Design for Manufacturability/Assembly Workshop Design for Serviceability/Maintainability Workshop Design to Cost Workshop Lean Product Development Workshop Mistake-Proofing by Design Workshop Quality Function Deployment (QFD) Workshop Target Costing Workshop Voice of the Customer Workshop About Firm Overview DRM Associates Consultants Consulting and Training Clients NPD Resources Papers and Articles NPD Body of Knowledge New Product Development Glossary Mistake-Proofing by Design Mistake-Proofing a product's design and its manufacturing process is a key element of design for manufacturability / assembly (DFM/A). Mistake proofing is also a key element of improving product quality and reliability and an element of the design for six sigma (DFSS) concept. A difficult to assemble product is more likely to be assembled incorrectly. The Japanese concept of Poka-Yoke (mistake-proofing) is oriented to finding and correcting problems as close to the source as possible because finding and correcting defects caused by errors costs more and more as a product or item flows through a process. Early work on poke-yoke by Japanese authorities like Shingo focused on mistake-proofing the process after a product has been designed and is in production. As time has passed, more emphasis has been placed on how the design of the product to avoid mistakes in production. Often the benefits of mistake-proofing not only help with production of the product, but can also contribute to correct user operation and maintenance of the product, and servicing of the product. The concept of Mistake-Proofing involves: Controls or features in the product or process to prevent or mitigate the occurrence of errors and/or; Requires simple, inexpensive inspection (error detect